Part 1: Parts Cannon!! Can it be saved? 95 Jeep Wrangler 4.0 https://youtu.be/XGx5cooQLQY
Part 2: Frustrating Diagnosis! It LIVES AGAIN! Jeep Wrangler 4.0 https://youtu.be/ZPBWAGcc-8M
Part 3: Old Jeeps Die HARD! Thermostatic Switch and Water Pump! 95 Wrangler 4.0
Part 4: Razor Sharp Gears!! NOT Good! Project Jeep 1995 Wrangler 4.0 https://youtu.be/Q5irXiktUbI
Past 5: Smallest Shaft Ever! FRIED Flywheel! | Project JEEP! 1995 Wrangler YJ https://youtu.be/p7x3vBUR-RQ
New “Wife unit” T-Shirts & Designs for the Season! https://youtu.be/6T_32dnOgTg
Customer States: Engine barely runs and has a severe lack of power. It also has the occasional no start or long cranking before it starts. So far I’ve found vacuum leaks, clogged ports, antifreeze leaks from the water pump and the electric fan is damaged. I had the fuel pump, filter, spark plugs, ignition wires, and a distributor cap and rotor. It also has a new coolant temp sensor, O2 sensor, MAP, intake temp, IAC and throttle position sensor replaced. The ECM / PCM has been replaced too. See part one.
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Merry Christmas to you and yours Ray
I'm an old wrench turner I worked as a mechanic 60 years , Ray works his way through problems that keeps us , me entertained, click. Thank you for your time and patience learning some new technology to everyone watching click,click.
The washer looks like a Belleville washer. A spring washer to maintain pressure if the nut comes loose.
I see no reason you could not have put in a few of the exhaust bolts (nuts) in before putting in the intake manifold. edit – yep. Watched farther.
I don't know if others have mentioned this, but the 4.O in-line six can trace it's lineage back to American Motors, who designed it's predecessor, the 232 CID straight six in 1966 (approx.) (The 4.0 is, in its core, a very old-school engine, full of 1960's Detroit technology.) At that time, pushrod six cylinder engines rare, if ever, had a crossflow cylinder head because the pushrods took up too much space where the ports would be fitted if it was a crossflow head.
I find that putting in studs on the bottom set of bolt holes for the manifold helps immensely in aligning and tightening that assembly. It is especially useful if that engine is installed in an XJ, MJ, or ZJ Jeep, where access to the lower bolts is much harder than on a YJ or TJ.
Door Trim Tool. I found one on the side of the road about 10 years ago. It is the handiest tool in my tool box. I don't know how I ever got along without one.
These kinds of vehicles are what drives dolly innovation. LOL Some external wheels to clear your lift.
Great video project! Love to see old Jeeps get some love. As for the 4.0L, AMC designed and went to production in 26 months. Just in time to be released in September of 1986 fo rthe '87 model year, much to the chagrin of Chrysler execs. Even though Chrysler execs had the purchase of AMC in the bag, prior to their actual takeover in January '87, they decreed the AMC 258 shall not be installed into the XJ platform even under the cries of customers demanding better power with a six. But AMC got around the order with the 4.0L borrowing some of the design cues from the 258. The XJ/MJ was designed for a V6, hence the short hood design but the absolute dog of GM, the 2.8L was what they could get by the 1984 debut instead of anything else. Fast forward to 5 million 4.0L engines made and more stringent upcoming emissions standards for 2007. Chrysler would not spend money to make it emissions compliant and thus the '06 model year was the last. They chose instead to install an engine from the minivan line into the new plastic JK Wrangler until their own Pentastar design was available.
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For those not in-the-know, you can use the 258 crank and rods with the stock 4.0L pistons and come out with a 4.5L with no other mods required. In terms of intake manifolds, both 'Log" and "Horseshoe" flow fairly equally despite the myth about the "Horseshoe" style intake being "a lot" better. In terms of the "best" head? The 7120 (lacking provision for the block's head locating dowel pins) or the 0630 (with the dowel pin locator holes) are the best flowing factory heads. Both heads will work on all 4.0L blocks. Only the raising roof of the exhaust port increases flow and in the case of the infamous 0331 smog head casting, was raised but over all made with a smaller cross-section to control emissions and still keep the engine legal without an EGR (which was deleted from the '91 and later using the Chrysler SBEC-II ECU).
You can do the exhaust with out removing the intake. It makes most of the work harder and unseen.
I did it on a 92 YJ with the 2.5l 4 banger and a 2000 XJ with the 4l 6.
Both because I did a cold deep water crossing with a really hot exhaust and cracked the cast bit.
Love all your videos mate.
Most likely wrong, but one or two of the freeze plugs looked like they were ready to fail?
Would wrapping the exhaust help mitigate issues that having the manifolds on the same side prevent?
Hi Ray keep up the good work and love your show. I have a 87 yj thinking of electric fan upgrade. Want to know what all needs to be done. Do I have to upgrade the charging system and everything to make it work
Ray that intake and exhaust closed to each other is to heat up in cold starting, they design that way like old carburetor electric choke
Super clean shiney shine shine!
The rectangle ports are the intake toe round ports are the exhaust you said the opposite
What brand is the 1/4" ratchet you are using? I'm always on the lookout for a long handle 1/4" and I can never find one.
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Hey, Ray, looks like you left your socket on that rear most nut on the exhaust manifold.
12:23 On the freeze plugs, is that corrosion working its way through?